In-line operation system and flow plan for manufacturing liquid crystal display

ABSTRACT

An in-line operation for manufacturing liquid crystal displays. First, a liquid crystal cell is pulled out from a first stocking region and placed inside a processing station by a loader. The liquid crystal cell is shunt, beveled and corner-cut by a shunt and bevel unit inside the processing station. The liquid crystal cell is next transferred directly to a brush-washing unit for cleaning. After cleaning, the semi-finished product is directly transferred from a linked stocking region to an affixing unit for attaching a polarizer onto the liquid crystal cell. The semi-finished product is transferred to a second stocking region by an unloader. Sample inspection can be carried out when the semi-finished product is still within the linked stocking region.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the priority benefit of Taiwanapplication serial no. 89127829, filed Dec. 26, 2000.

BACKGROUND OF THE INVENTION

[0002] 1. Field of Invention

[0003] The present invention relates to a method of manufacturing liquidcrystal display (LCD). More particularly, the present invention relatesto an in-line operation system and flow plan for manufacturing liquidcrystal display.

[0004] 2. Description of Related Art

[0005] Liquid crystal display (LCD) is incorporated into a variety ofconsumer electronic and computer products such as portable televisions,mobile telephones, camcorders, notebook computers, desktop monitors andprojection televisions. Major advantages of a LCD include itshigh-quality picture, light and streamline body, low voltage driver andlow power consumption. Hence, LCD is gradually replacing cathode raytube (CRT) as the preferred means of display.

[0006] The main body of a liquid crystal display is a liquid crystalunit consisting of two transparent panels and a layer of liquid crystalbetween the panels. At present, thin film transistor (TFT) is thedominant type of liquid crystal display. In general, the manufacturingof a TFT type LCD can be grouped into three stages: the production ofthe thin film transistor (TFT) array, the assembly of the liquid crystalcell and the fabrication of the liquid crystal module.

[0007] In the production of a TFT LCD, the production of a TFT arrayincludes producing a thin film transistor panel. The assembly of theliquid crystal unit includes joining two thin film transistor panelstogether and injecting liquid crystal into the space between the panelsto form a liquid crystal unit. The fabrication of the liquid crystalmodule includes attaching a polarizer to the liquid crystal displaypanel, connecting the circuit inside the liquid crystal display panelwith a driver IC and installing of reflectors or back lights. Finally,burn-in testing is conducted after the module is formed.

[0008] At present, off-line operation is employed in the production of aliquid crystal display from liquid crystal cell assembly to liquidcrystal module assembly. FIG. 1 is a flow chart showing the steps in aconventional off-line operation method for fabricating liquid crystaldisplay from the assembly of liquid crystal cell to the assembly ofliquid crystal module. As shown in step 100 of FIG. 1, the semi-finishedproduct after liquid crystal is sealed in the space between liquidcrystal panels is placed in a first stocking region. In step 102, thesemi-finished product is pulled by a loader from the first stockingregion. In step 104, the completely assembled liquid crystal cell isshunt-separated, beveled and corner-cut. In step 106, cullets that formdue to the cutting, the beveling and the corner smoothing operations areremoved. In step 108, the semi-finished is further cleaned by brushwashing. In step 110, the semi-finished product is placed in a secondstocking region using an unloader.

[0009] As shown in FIG. 1, the semi-finished product is pulled from thesecond stocking region in step 112 to perform a visual inspection aftercompleting the steps for producing a liquid crystal cell. In step 114,the semi-finished product is placed in a third stocking region ready sothat the semi-finished product can be pulled from the third stockingregion when liquid crystal module needs to be fabricated. Hence, betweenthe assembly of the liquid crystal cell and the assembly of the liquidcrystal module, the semi-finished product is unloaded from theproduction line and stored in a stocking buffer, typical for an off-lineoperation.

[0010] To fabricate the liquid crystal module as shown in FIG. 1, theinspected liquid crystal display cell is pulled out from the thirdstocking region by a loader in step 116. In step 118, the liquid crystalcell is brush-washed to clean all the exposed surfaces. In step 120, apolarizer is affixed to the surface of the liquid crystal cell. In step122, the semi-finished product is unloaded from the production line to afourth stocking region ready for subsequent use.

[0011] However, because of the selection of off-line operation betweenthe assembly of the liquid crystal cell and the assembly of liquidcrystal module, a production line with a length of at least 50m to 60mis required.

SUMMARY OF THE INVENTION

[0012] Accordingly, one object of the present invention is to provide anin-line operation installation and flow plan that uses a linked stockingregion to directly connect the assembly line for producing liquidcrystal cell and the assembly line for producing liquid crystal module.By automating the transfer of semi-finished product between the twoassembly lines, the number of stocking regions, processing machines andoperators needed in the production line is reduced. By carrying out asingle brush washing instead of a cullet cleaning and a brush washingoperation, length of the production line can be reduced withoutaffecting product yield. In addition, by linking an inspection cell witha connected stocking region, the semi-finished product can be inspectedon line rather than off line in a full visual inspection. Without offline inspection, production time and area needed for production arereduced. Hence, product cycle is reduced, product yield is increased andproduction line administration is simplified.

[0013] This invention also provides an in-line operation formanufacturing liquid crystal displays. First, a liquid crystal cell ispulled out from a first stocking region and placed inside a processingstation by a loader. The liquid crystal cell is shunt, beveled andcorner-cut by a shunt and bevel unit inside the processing station. Theliquid crystal cell is next transferred directly to a brush-washing unitfor cleaning. After cleaning, the semi-finished product is directlytransferred from a linked stocking region to an affixing unit forattaching a polarizer onto the liquid crystal cell. The semi-finishedproduct is transferred to a second stocking region by an unloader.Sample inspection can be carried out when the semi-finished product isstill within the linked stocking region. The inspected semi-finishedproduct passing through the linked stocking region can be brush-washed asecond time before transferring to the affixing unit for attaching apolarizer. The second brush-washing unit is inserted between the linkedstocking region and the affixing unit.

[0014] In addition, this invention provides an in-line operation systemthat includes a stocking region for holding liquid crystal cell, a shuntand bevel unit, a brush-washing unit, a linked stocking region, anaffixing unit, an inspection unit and a second stocking region forholding semi-finished liquid crystal module. The brush-washing unit, theinspection unit, the shunt and bevel unit, the linked stocking regionare joined together. Furthermore, the shunt and bevel unit may include adirectly attached loader while the affixing unit may include a directlyattached unloader. A second brush-washing unit that joins up directlywith the affixing unit and the linked stocking region may be added.

[0015] It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary, andare intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawings illustrate embodiments of theinvention and, together with the description, serve to explain theprinciples of the invention. In the drawings, FIG. 1 is a flow chartshowing the steps in a conventional off-line operation for fabricatingliquid crystal display from the assembly of liquid crystal cell to theassembly of liquid crystal module;

[0017]FIG. 2 is a flow chart showing the steps in an on-line operationfor fabricating liquid crystal display by integrating the assembly ofliquid crystal cell and liquid crystal module according to a firstpreferred embodiment of this invention, FIG. 3 is a schematic diagramshowing an on-line operation system for fabricating liquid crystaldisplay by integrating the assembly of liquid crystal cell and liquidcrystal module according to the first preferred embodiment of thisinvention;

[0018]FIG. 4 is a flow chart showing the steps in an on-line operationfor fabricating liquid crystal display by integrating the assembly ofliquid crystal cell and liquid crystal module according to a secondpreferred embodiment of this invention; and

[0019]FIG. 5 is a schematic diagram showing an on-line operation systemfor fabricating liquid crystal display by integrating the assembly ofliquid crystal cell and liquid crystal module according to the secondpreferred embodiment of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Reference will now be made in detail to the present preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Wherever possible, the same reference numbers areused in the drawings and the description to refer to the same or likeparts.

[0021]FIG. 2 is a flow chart showing the steps in an on-line operationfor fabricating liquid crystal display by integrating the assembly ofliquid crystal cell and liquid crystal module according to a firstpreferred embodiment of this invention. FIG. 3 is a schematic diagramshowing an on-line operation system for fabricating liquid crystaldisplay by integrating the assembly of liquid crystal cell and liquidcrystal module according to the first preferred embodiment of thisinvention.

[0022] In this invention, some of the steps for assembling a liquidcrystal cell are similar to the conventional technique. When the liquidcrystal is sealed inside liquid crystal display panels, fabrication ofthe liquid crystal cell is considered complete. As shown in FIGS. 2 and3, a liquid crystal cell 300 is placed into a first stocking region 302in step 200. To carry out subsequent processing, the liquid crystal cell300 is pulled out from the first stocking region 302. The first stockingregion 302, for example, can be the interior of an automatic stockingmachine.

[0023] In step 202, a loader 304 is used to pull out the semi-finishedliquid crystal cell 300 from the first stocking region 302. In step 204,the semi-finished liquid crystal cell 300 is transferred by the loader304 into a shunting and beveling unit 306. Inside the shunting andbeveling unit 306, the liquid crystal cell 300 is shunt, beveled andcorner-cut. The shunt and bevel unit 306 and the loader 304 are directlyjoined together.

[0024] In step 206, the shunt, beveled and corner-cut semi-finishedliquid crystal cell is transferred directly from the shunt and bevelunit 306 to a brush-washing unit 308. Any cullets formed on the liquidcrystal cell inside the shunt and bevel unit 306 are cleared away. Thebrush-washing unit 308 and the shunt and bevel unit 306 are directlyjoined together. This invention uses a single brush-washing step 206 toreplace the conventional method of performing a cullet-cleaning in step106 and performing a brush washing in step 108 as shown in FIG. 1.Hence, one cullet-cleaning step is saved. In step 208, the brush-washedsemi-finished product is directly transferred from the brush-washingunit 308 to a linked stocking region 310. From the linked stockingregion 310, the semi-finished product is distributed to other processingunit. The linked stocking region 310 and the brush-washing unit 308 aredirectly joined together. In addition, the interior of the linkedstocking region 310 has clean-room control facilities.

[0025] In step 210, the liquid crystal cell is directly transferred fromthe linked stocking region 310 to an affixing unit 312. Inside theaffixing unit 312, a polarizer 314 is attached to one of the liquidcrystal cell surface 300a to carry out liquid crystal module assembly.The affixing unit 312 and the linked stocking region 310 are directlyjoined together.

[0026] One major aspect of this invention is the joining of thebrush-washing unit with the affixing unit through the linked stockingregion. Hence, the liquid crystal cell assembly line and the liquidcrystal module assembly line are merged together. Consequently, thebrush-cleaned semi-finished products can be directly transferred fromthe brush-washing unit to the affixing unit. The automatic transfer ofsemi-finished product between the liquid crystal cell assembly line andthe liquid crystal module assembly line is what constitutes the in-lineoperation method according to this invention.

[0027] In addition, the linked stocking region 310 and an inspectionunit 316 are directly joined together as shown in FIG. 3. A sampleinspection such as a visual check of the semi-finished liquid crystaldisplay can be carried out in the inspection unit 316 in step 214. Anyproduct containing defects is removed from the production line forfurther treatment or rework. After treatment or rework, thesemi-finished product can be returned to the inspection unit 316. Afterproper inspection in the inspection unit 316, the semi-finished productis transferred to the linked stocking region 310 to continue with theremaining processing steps. Furthermore, if there are errors in any oneof the processing steps, the semi-finished products on the productionline can be removed from the linked stocking region 310. When the causeof error is removed, the reworked semi-finished product can be returnedto the linked stocking region 310 so that the remaining operations canbe carried out.

[0028] In step 212, the polarizer affixed semi-finished product ispulled out from the affixing unit 312 and transferred to a secondstocking region 320 by an unloader 318. The unloader 318 and theaffixing unit 312 are directly joined together. The second stockingregion 320 is a stocking region for semi-finished products. For example,the second stocking region 320 can be an automatic stocking machine.

[0029]FIG. 4 is a flow chart showing the steps in an on-line operationfor fabricating liquid crystal display by integrating the assembly ofliquid crystal cell and liquid crystal module according to a secondpreferred embodiment of this invention. FIG. 5 is a schematic diagramshowing an on-line operation system for fabricating liquid crystaldisplay by integrating the assembly of liquid crystal cell and liquidcrystal module according to the second preferred embodiment of thisinvention.

[0030] In the second embodiment of this invention, a portion of thesteps in the liquid crystal cell assembly and liquid crystal moduleassembly is identical to the first embodiment. When the liquid crystalis sealed inside liquid crystal display panels, fabrication of theliquid crystal cell is considered complete. As shown in FIGS. 4 and 5, aliquid crystal cell 500 is placed into a first stocking region 502 instep 400. To carry out subsequent processing, the liquid crystal cell500 is pulled out from the first stocking region 502. The first stockingregion 502, for example, can be the interior of an automatic stockingmachine. 15 In step 402, a loader 504 is used to pull out thesemi-finished liquid crystal cell 500 from the first stocking region502. In step 404, the semi-finished liquid crystal cell 500 istransferred by the loader 504 into a shunting and beveling unit 506.Inside the shunting and beveling unit 506, the liquid crystal cell 500is shunt, beveled and corner-cut. The shunt and bevel unit 506 and theloader 504 are directly joined together.

[0031] In step 406, the shunt, beveled and corner-cut semi-finishedliquid crystal cell is transferred directly from the shunt and bevelunit 506 to a first brush-washing unit 508 a.

[0032] Any cullets formed on the liquid crystal cell inside the shuntand bevel unit 506 are cleared away. The first brush-washing unit 508aand the shunt and bevel unit 506 are directly joined together. In thisembodiment, a single brush-washing step is used instead of theconventional method of performing cullet-cleaning brush washing as shownin FIG. 1 to save one cullet-cleaning step. In step 408, thebrush-washed semi-finished product is directly transferred from thefirst brush-washing unit 508 a to a linked stocking region 510. From thelinked stocking region 510, the semi-finished product is distributed toother processing unit. The linked stocking region 510 and the firstbrush-washing unit 508 a are directly joined together. In addition, theinterior of the linked stocking region 510 has clean-room controlfacilities.

[0033] In step 410, the liquid crystal cell is directly transferred fromthe linked stocking region 510 to a second brush-washing unit 508 b.Inside the second brush-washing unit 508 b, surface of the liquidcrystal cell is thoroughly cleansed. The second brush-washing unit 508b, similar to the first brush-washing unit 508 a, is directly joinedwith the linked stocking region 510. Similar to the first embodiment,the liquid crystal cell assembly line and the liquid crystal moduleassembly line are integrated together through the joining of the firstbrush-washing unit, the linked stocking region and the secondbrush-washing unit. The automatic transfer of semi-finished productbetween the liquid crystal cell assembly line and the liquid crystalmodule assembly line is what constitutes the in-line operation methodaccording to this invention.

[0034] In step 412, the cleaned liquid crystal cell is directlytransferred from the second brush-washing unit 508 b to an affixing unit512. Inside the affixing unit 512, a polarizer 514 is attached to one ofthe liquid crystal cell surface 500 a to carry out liquid crystal moduleassembly. The affixing unit 512 and the second brush-washing unit 508 bare directly joined together.

[0035] Similar to the first embodiment, the linked stocking region 510and an inspection unit 516 are directly joined together as shown in FIG.3. A sample inspection such as a visual check of the semi-finishedliquid crystal display can be carried out in the inspection unit 516 instep 416. Any product containing defects is removed from the productionline for further treatment or rework. After treatment or rework, thesemi-finished product can be returned to the inspection unit 516. Afterproper inspection in the inspection unit 516, the semi-finished productis transferred to the linked stocking region 510 to continue with theremaining processing steps.

[0036] In step 414, the polarizer affixed semi-finished product ispulled out from the affixing unit 512 and transferred to a secondstocking region 520 by an unloader 518. The unloader 518 and theaffixing unit 512 are directly joined together. The second stockingregion 520 is a stocking region for semi-finished products. For example,the second stocking region 520 can be an automatic stocking machine.

[0037] According to the embodiment of this invention, the advantages ofthis invention can be summarized as follows:

[0038] 1. The in-line operation of this invention uses a linked stockingregion to integrate the liquid crystal cell assembly line and the liquidcrystal module assembly line together. Hence, semi-finished products canbe automatically transferred between the two assembly lines, therebysaving a few automatic stocking machines, a number of loaders andunloaders for off-line operation, operators and hence reducing equipmentand production cost.

[0039] 2. This invention not only uses the linked stocking region tojoin the liquid crystal cell assembly line and the liquid cell moduleassembly line, but also uses a single brush-washing step instead ofseparate cullet-cleaning and brush-washing step. Therefore, acullet-cleaning machine is saved without affecting product quality.Since overall length of the production line is somewhere between 25m to30m, the cost of investment, production management, production cycle isreduced.

[0040] 3. By joining the linked stocking region with an inspection cell,the semi-finished product passing the linked stocking region can bevisually inspected without having to provide space and time for off-lineinspection. Thus, production cost is reduced and product yield isincreased.

[0041] It will be apparent to those skilled in the art that variousmodifications and variations can be made to the structure of the presentinvention without departing from the scope or spirit of the invention.In view of the foregoing, it is intended that the present inventioncover modifications and variations of this invention provided they fallwithin the scope of the following claims and their equivalents.

What is claimed is:
 1. An in-line operation for fabricating liquidcrystal display, comprising the steps of: pulling a liquid crystal cellfrom a stocking region; transferring the liquid crystal cell to a shuntand bevel unit for carrying out shunting, beveling and corner-cuttingoperation; transferring the liquid crystal cell to a brush-washing unitthat joins directly with the shunt and bevel unit for brush-cleaning;transferring the liquid crystal cell to a linked stocking region thatjoins directly with the brush-washing unit and then transferring theliquid crystal cell from the linked stocking region to an affixing unitthat joins directly with the linked stocking region; and attaching apolarizer onto a surface of the liquid crystal cell.
 2. The in-lineoperation of claim 1, wherein the step of pulling out a liquid crystalcell from the stocking region includes using a loader.
 3. The in-lineoperation of claim 1, wherein the step of transferring the liquidcrystal cell into the linked stocking region further includes performinga sample inspection of the liquid crystal cell.
 4. The in-line operationof claim 1, wherein after the step of transferring the liquid crystalcell into the linked stocking region but before attaching a polarizerinside the affixing unit, further includes cleaning the attach surfaceof the liquid crystal cell.
 5. The in-line operation of claim 1, whereinafter the step of attaching a polarizer onto the surface of a liquidcrystal cell, further includes transferring the liquid crystal cell intoa semi-finished product stocking region.
 6. The in-line operation ofclaim 5, wherein the step of transferring the liquid crystal cell intothe semi-finished product stocking region includes using an unloader. 7.An in-line operation system for fabrication liquid crystal display,comprising: a loader for pulling out a plurality of liquid crystal cellsfrom a first stocking region; a shunt and bevel unit joined directlywith the loader for shunting, beveling and corner-cutting each liquidcrystal cell; a brush-washing unit joined directly with the shunt andbevel unit for brush-cleaning each liquid crystal cell; a linkedstocking region joined directly with the brush-washing unit fortransferring each liquid crystal cell; an affixing unit joined directlywith the linked stocking region for attaching a plurality of polarizersonto the respective surface of each liquid crystal cell; and an unloaderjoined directly with the affixing unit for transferring thepolarizer-attached liquid crystal cell to a second stocking region. 8.The in-line operation system of claim 7, wherein the system furtherincludes an inspection unit joined directly with the linked stockingregion for inspecting the passing liquid crystal cell.
 9. An in-lineoperation system for fabricating a liquid crystal display, comprising: aloader for pulling out a plurality of liquid crystal cells from a firststocking region; a shunt and bevel unit joined directly with the loaderfor shunting, beveling and corner-cutting each liquid crystal cell; afirst brush-washing unit joined directly with the shunt and bevel unitfor brush-cleaning each passing liquid crystal cell; a linked stockingregion joined directly with the first brush-washing unit fortransferring each liquid crystal cell; a second brush-washing unitjoined directly with the linked stocking region for brush-cleaning eachpassing liquid crystal cell; an affixing unit joined directly with thesecond brush-washing unit for attaching a plurality of polarizers ontothe respective surface of each liquid crystal cell; and an unloaderjoined directly with the affixing unit for transferring thepolarizer-attached liquid crystal cell to a second stocking region. 10.The in-line operation system of claim 9, wherein the system furtherincludes an inspection unit joined directly with the linked stockingregion for inspecting the passing liquid crystal cell.